Method of forming corrugated car ends



A. w. FRASER 2,213,648

Sept. 3, 1940.

Original Filed March 14, 1935 INVENTOR ALEXANDER W. FRASER I Oil ATTORNEYS Sept. 3, 1940. A. w. FRASER METHOD OF FORMING CORRUGATED CAR ENDSOriginal Filed March 14, 1935 3, Sheets-Sheet 2 w z 4 I a 2 0 I. Z 4 u a1- E 7 H II? m m rd m 2/ FM m u A n U W m 1 n u A, "I m H M: 6 m i H u au f n L n f 4 u u 2 n u m w a m m: m .m m: 1 m: n W & IILIUL: Lt: a T 45 l INVENTOR ALEXANDER W. FRASER ATTORNEYS Sept. 3, 1940. A. w. FRAiiERMETHOD OF FORMING CORRUGATED CAR ENDS Original Filed Mafch 14, 1935 3Sheets-Sheet 3 ATTORNEYS Patented Sept. 3, 1940 UNITED STTES AENT()FFICE METHOD OF FORMIN G CORRUGATED CAR DS Alexander W. Fraser,Hamilton, Ontario, Canada, assignor to National Steel Car Corporation,Limited, Hamilton, Ontario, Canada, a corporation of Canada 1937, SerialNo. 120,852

Claims.

The invention relates in general to a method of forming corrugations insteel car ends, car sides, car doors and similar heavy metal structuralparts of railroad cars and otherbuilding constructions, and theinvention specifically relates to an improved method for formingcorrugated car ends, referred to in my Patent No. 2,079,553 granted May4, 1937 for Power press, of which this application is a division.

The car ends in the said application are characterized by having areinforcing corrugated area spaced inwardly from the outlining edges andin which the corrugated area is formed of two sets 1 of corrugations,with the corrugations of each set extending parallel to each other; thecorrugations of one set intersecting the corrugations of the other setto form a checker-board design and wherein the corrugations are each ofa U-shaped fiat web and inclined side wall type, with relatively narrowcorrugations forming one set identified as vertical posts extending withuniform cross sectional configuration from end to end, hurdling oroverlapping the relatively wide horizontal corrugations of the otherset, sometimes hereinafter identified as horizontal girders.

The primary object of the invention is to provide an improved andsimplified method of forming intersecting corrugations in heavy steel orequivalent metal plates and, specifically, to provide a simplified meansfor forming the corrugated area of the said application car end.

Corrugated car ends of the type under discussion are usually formed inone or more sections with dimensions when formed of one piece,substantially eight or nine feet Wide, four to five feet high, and witha thickness of three to five sixteenths of an inch, and are usually madeby die pressing high grade rolled sheet steel. It is the usual practiceto form one of the sections constituting the car end in a singledie-stamping operation and this procedure necessitates certainrefinements of practice, such for instance, as the maintaining of thislarge area plate at a relatively high temperature and the employment oflarge sized presses of the order of two thousand five hundred tonpresses.

The present method features the forming of the corrugated area of suchplates by die-pressing relatively small portions of the plate in each ofa series of succeeding stamping operations, and the forming ofcorrugations in plates of large area on a relatively small size press.In one method of practicing the invention, the corrugations can beformed on a press of relatively low capacity, such as a one thousand tontype of press, thus permitting of the fabrication of heavy typedie-pressing of car ends on presses commonly found in the ordinary carand railroad repair shops.

Briefly, the method consists in using a die press having means in itstwo coacting dies for forming two parallel corrugations in the plate,with the two corrugations properly spaced apart, together with theassociated intersecting part or parts of all of the transverselyintersecting corrugations required in the finished plate. The method ispracticed by feeding a fiat plate between the coacting dies of the pressand in the first step initially forming the first of the series ofparallel corrugations with their respective portions of the verticalhurdling corrugations, or rather partly forming the first set ofcorrugations at the beginning of the first press movement, and,subsequently, during the final movement of the first press movementcompleting the formation, if not already formed, of the first set ofcorrugations, and simultaneously forming the second set of identicalcorrugations. Then, separating the dies and reheating, if necessary, theportion of the plate next to be worked upon, the plate is advanced so asto locate the second succeeding horizontal wide corrugation on the diewhich had just previously formed the corresponding wide oorrugation ofthe first set, and then using the first corrugation-forming die as aholding means to die form the third corrugation, or rather third set ofcorrugations. The operation is continued with the last-formed widecorrugation advanced into and then held by the most advanced part of thedie, while the rear part of the die is forming the next succeeding widecorrugation and associated parts, all operations being preferablypracticed with a clamp forming part constituting the rear portion of thedie acting to hold the portion of the plate next to be worked upon inits original portions so as to prevent buckling in parts of the endintended to be fiat,

The invention also features the utilization of- 40 flat condition aswell as the outlining marginal a tions, while holding the material notyet worked, or intended not to be worked upon, from any incidentalwarping.

Still another object of the invention is to form the desired corrugatedarea with that nicety of control of the material being worked upon topermit the formation of the required corrugations without undulythinning out the material forming each corrugation and the providing ofthat degree of clamping intensity of the metal being worked upon whichwill permit a relatively cold fiow of material to the part forming thecorrugation and at the same time minimize, if not eliminateobjectionable buckling in the parts immediately adjacent the corrugationbeing formed.

This phase of the invention is provided by utilizing a work-holdingclamp as part of the corrugation forming which will hold the flatportions of the plate adjacent and outlining the portion at the timebeing formed into corrugations, with an intensity of clamping actionsufficiently great to prevent buckling but not so high as to prevent thedesired edgewise creeping of the material from the uncorrugated into theportion in which the corrugation is being formed for the time being. Inthis connection it is suggested that the work holding clamp have aslightly greater clearance at the intake end of the material than at thedischarge end adjacent the corrugation forming side thereby tofacilitate feeding of the plate into the portion being corrugated.

Various other objects and advantages of the invention will be in partobvious from a consideration of the method features of the disclosureand from an inspection of the accompanying drawings and in part will bemore fully set forth in the following particular description of onemethod of practicing the invention, and the invention also consists incertain new and novel modifications of the preferred method as well asto the products produced following such method or methods.

In the accompanying drawings:

Figs. 1 to 5 are explanatory views illustrated as if in end elevation ofa die press showing successive steps in corrugating sheet metal inpracticing the method herein featured;

Fig. 6 is an enlarged plan view of opposite .ends of the lower die shownin the preceding figures and with the midportion broken away; 7

Fig. '7 is a view in elevation of the upper die looking at the same fromthe right side of the showing in Figs. 1 to 5;

Fig. 8 is a similar view of the companion parts of the lower die;

Fig. 9 is a view in elevation of the lower right hand corner of a carend constructed by following the method herein featured. It can beassumed also that either the lower or upper half of this figure alsorepresents a plan View of either one of the dies shown in end elevationin the preceding figures, it being understood, of course, that both theupper and lower dies are each of twice the length of the showing in Fig.1; and

Fig. 10 is a perspective view of a portion of the car end shown in Fig.1, showing one of the vertical corrugations intersecting two of thehorizontal corrugations, but likewise it can be assumed that the showingin Fig. 10 is a portion of one of the dies which forms thecorrespondingly shaped portion of the car end.

Fig. 11 is a view of the die press shown in Figs. 1 to 4 andillustrating the position of the parts during the instant of time duringthe descent of the upper die immediately following the position shown inFig. 1 and before the die has completely seated as shown in Fig. 2; and

Fig. 12 is a perspective view of the partly formed blank if removed fromthe press at the Fig. 11 stage of the initial die pressing.

Referring to the finished structure, there is eventually formed asubstantially flat sheet metal plate or panel ll] having inturned sideflanges I I and an outlining flat uncorrugated edge portion 12; Withinthe outlining fiat edge area l2 the plate is provided with two sets ofcorrugations to form a central reinforced area to the panel as a wholeone set of corrugations It being relatively numerous extendshorizontally in parallel relation and the copending disclosure featuresthe forming of these corrugations equidistantly spaced apart to formintegral girders in the finished plate. The other set of corrugations itbeing less numerous and in the instant case constituting four, arerelatively narrow and extend vertically, and like the horizontalcorrugations in the copending disclosure feature the forming of thesevertical corrugations substantially equidistantly spaced aparthorizontally. These corrugations intersecting each other at right anglesto form an elongated block-like or checkerboarddesign over the entirereinforced area. The trough or channel [5 of the girder formingcorrugation I3 is continuous across the entire reinforced area and isstraight from end to end. The trough or channel I6 of the post formingcorrugation I4 is likewise continuous from end to end across thereinforced area but of course is not straight being of undulatory form.The post forming corrugations M are continuous and project outwardly notonly from the fiat uncorrugated portion of the plate but extend up thesides of, pass over and project beyond the corrugations l3 as shown at18, Fig. 10. The posts Hi then extend over the girder formingcorrugations l3 and along the trough or uncorrugated space 29 formedbetween the adjacent pairs of the girder forming corrugations I3.

Referring to the showings in Figs. 1 to 8 it will be understood thatthere is illustrated a conventional form of die pressing machineincluding a stationary bed 2! and a movable power actuated plunger 22mounted for vertically reciprocatory movement. A relatively stationarytwo part male die 23 is carried by the bed 2| on the upper side thereofand the plunger 22 is provided on its underside with a one-piececoacting female die 24.

The die 23 is formed primarily of two relatively movable parts: amiddle, long rectangular bar or strip 25 rigidly secured to the bed 2|,and an encircling or rather middle bar-enclosing, rectangular, hollowframe. The frame includes two long outside strip bars or plates 26 and21, extending parallel to and in edgewise vertical sliding engagementwith opposite long sides of the middle strip 25 and two connecting endmembers or blocks 42 and Q3. The strips 26 and 21 ment in the bed bymeans of supporting legs 28 passing through the'bed 2i, through abolster All carried by a press bed 38 and resting on top of a pressurecushion Q9 guided for vertical -move-.

ment in the press bed. The frame is normally I maintained in positionelevated above the bed 2!,

by means of cushioning springs 59 bearing upwardly against the pressurecushion G9, or, in some forms of such presses by pneumatic cushions, orplungers, such as are commonly found in presses of this character. Inthe instant case the pads having a resistance to being depressed equalto. about one fifth of the force inherent in the plunger 22 acting todepress the pad forming frame. The strip 26 has a smooth top face 29 andconstitutes in the right hand side of the showing one of the elements ofa flat-face workholding jaw or clamp for securing the work plate ashereinafter outlined. The top surface of strip 26 is continuous and onthe same level with the top surface of the end blocks 32 and 43 and withthe fiat faces of the strips 25 and 21.

The middle strip 25 and the outside strip 21 are each provided with alongitudinally extending rib one being the duplicate of the otherdesignated respectively 30 and 3i, each designed to form any and all ofthe girder forming corrugations l3 and each half length of said ribhaving the shape in plane shown at any of the strips marked H3. The topface of each of these strips 25 and 27 is provided on opposite sides ofthe base of its rib with a flat top face; the faces on opposite sides ofrib 38 marked- 3! and 32 and. the similar faces on opposite sides of rib3i marked 33 and 34. The two top faces 35 and 34 when in the positionshown in Figs. 3 and maintain the trough or uncorrugated spaces in thefinished structure.

The top, die-forming surface of each of the strips and 21 is alsoprovided with a plurality, in the instant case with four, transverselyextending beads 35 and 36, one for forming each of the upstandingrelatively narrow corrugations M. It is understood, of course, that eachbead extends when the pad 27 is in its lowermost position continuouslyacross and between the two ribs 32 and 3|. 1

' The die 24 is formed as the negative or complement of the two part die23, except that the portion 31 immediately above and forming thecoacting element of the clamp jaw 26 is formed fiat and preferablypolished as is the top face of the floating clutch element 28 but has agreater clearance at its outer edge, as indicated at 38, than at itsinner edge 39 when the die elements. are in their proper corrugationforming relation. The left two-thirds of the underside of the die 24- isprovided with two identical channels 40 and ll for receivingrespectively the ribs 36 and 3i and with transversely extending smallergrooves 42,-

one for each of the beads 3536. When viewed in plane, a part of theunderside of die 25 corresponds to the showing in Fig. 10 in itsinclusion of two grooves I5 and one of the transverse grooves it.

It will beunderstood that the press is provided with conventional partssuch, for instance, as a crank 5| actuated by a main gear 52 in meshwith a source of power indicated by the pinion drive 53 forreciprocating the plunger 22, as means for adjusting the cushioningtension on the floating pads, feed tables for feeding the stock to thepress and for withdrawing the finished product from the press and withguides and templets for locat- Idirection indicated by the arrows inFigs. 1 and 10 until the advanced edge e meets a stop (not shown) butlocated to bring the channel H5 at I the upper edge of the end plate asshown in Fig. 9. Other stops are used to insure the requisite width ofedge portion !2 and flange II tothis particular piece of work. At thistime the plate assumes roughly the position indicated in Fig. 1.

Power is then turned on to lower the plunger 22 and during the loweringmovement of its initial operation two actions take place. First, theleft portion of the coacting dies, that is the pad 21 andthe coactingpart immediately above the same, catches the portion of the platetherebetween and the entire frame and with it the pad 21 is loweredagainst the resistance of the frame holding springs.

These springs are so tensioned relative to the plate being worked uponthat the associated die parts begin to form the first corrugation markedI3 Fig. 9. As the upper die bears down on the plate 23 the firstcorrugation I3 begins to form somewhat semi-circular in cross section asshown at l5 with the beginnings of the associated hurdling corrugation Mas shown by the two transversely aligned humps Ma and Mb as shown inFig. 12. As the top die continues to-move down beyond the position shownin Fig. 11 towards the position shown in Fig. 2, these humps Ma and Mbwill gradually increase in length both towards each other until theyunite and away from each other until they form the complete hurdlingportion of the length indicatedbyl l in Fig. 9. At the end of this stepthe parts are at least approximately in the position shown in Fig. 2. Bythis time the upper die has taken up the clearance between the clampelements 26-31 and their connecting end pieces but the die parts formedby 1 the middle strip 25 and the corresponding parts above the same havenot yet contacted or have just about contacted with the uncorrugatedportion of the plate therebetween;

As the upper die continues to lower, the first corrugation I3 is more orless completely formed. By the time the top die has finallyclosed'completely on the bottom die asshown in Fig. 2 but before thefloating die 21 commences to move down there is formed not only thecorrugation I3 but the intersecting portions of each of .thecorrugations M embraced within the bracket marked I3 Fig. 9. It willthus be seen that the advanced edge of the plate is held between theleft hand portion of the dies and is held from movement in the directionof advance of the plate (shown by the arrow) by the rib 3l,-and is heldfrom lateral movement in the transverse direction by the severalsections M of thetrans versely extending corrugations engaging over thebeads. 36. While this advanced corrugated portion of the plate is thusbeing held with any deelements with sufficient intensity to preventthis" part of the plate from buckling, but with suflicient slipping topermit the held portion of the 75" ond corrugation in position betweenthe die ele- 252l-4243 is being pressed firmly into engagement with thebed 2i and both of the corru gations forming parts of the dies havecompleted their final pressing action so that at the end of the stepindicated in Fig. 3, the first two corrugations I3 I3 have'beencompletely formed, and the adjacent fiat portions surrounding the samehave been kept flat.

' The upper die is then elevated to its normal raised position and thecorrugated edge of the plate is then raised out of engagement with thelower die elements. The plate is then advanced one step in the directionof the arrows and into its next succeeding position in the die assembly,the second corrugations E3 being located on the rib 3| of the floatingpad 21, and, of course, with the transverse corrugation portion I lfitted over the beads 36 of this floating pad and the parts are then inposition to form the third corrugation I3 The plunger is lowered withthe second or succeeding stroke of the machine, first into the positionshown in Fig. 4 so as to clamp the secments and in this way to hold thesecond corrugation firmly in place during the operation of forming thethird corrugation. The third corrugation is formed beginning with theposition of the dies as shown in Fig. 4 and ending with the position ofthe dies as shown in Fig. 5, at which time the third corrugation I3 andits associated transverse portions M are formed, while the surroundingfiat portion is held in such fiat position.

It will be understood that this operation is repeated, each previouslyformed corrugation being utilized as a holding and spacing meanstolocate the next succeeding parallel wide corrugation and associated partof the continuous transverse corrugations until the required area hasbeen formed with its arrangement of intersecting corrugations.

By practicing the method herein disclosed it is possible to form aone-piece corrugated car end or similarly large construction unitwithout necessity of using the powerful presses heretofore foundnecessary in pressing car ends into their requisite corrugated forms.

As each corrugation after the first is formed by the same die part 25and the coacting part im mediately above 25, it follows that all of thewide corrugations 13 are of identical contour and that at the end of theprocedure each transverse corrugation I4 is of identical conformationthrough its length, thus providing a car end of any desired number ofcorrugations l3 formed from a die' assembly composed only of twocorrugation forming parts. Even though the high, or most advanced,portions l8 of the corrugations M are pressed out of the plane of thefiat sheet considerably in advance of the depth of the channels I5, therefinement practiced in this method of permitting the creeping of theplate into the portion being formed into corrugations results in formingeach corrugation separately without appreciably thinning out the metalas it is curved into the U-form in cross section characterizing thecorrugations in the finished plate. Finishing the clamping faces of thejaw elements with'a machine smooth finish minimizes frictionalresistance to the advance of the metal into the trough forms while theportion of the plate next to be corrugated, as well as the outliningedge portions, are'held in their initial fiat condition and are thusfreed from strain and lines of weakness which might otherwise occur whenthe flat portions are subsequently subject to the action of thecorrugation forming dies. It will be understood, of course, that theclearance illustrated in Figs. 1 to 5 between the jaw elements has beenpurposely exaggerated in order to show it, but in" actual practice theincrease in clearance is slight and the action might be more properlydesigned in the art without departing from the spirit of the invention.

I claim: 1. In the art of forming corrugated metal car ends of the typein which the corrugated area isformed of a set of parallel corrugationsof relatively large number, extending horizontally and spaced verticallyin the finished end, and a second set of parallel corrugations ofrelatively small number extending vertically and spaced aparthorizontally and intersecting the horizontal corrugations in thefinished end, and which corrugated area is surrounded by a flatuncorrugated outlining marginal portion,- the method which consists indie forming in a flat sheet of heated metal the first two horizontalcorrugations and so much of the vertical corrugations as intersect thesaid first two horizontal corrugations, the die forming area beinglocated with the first of said two corrugations adjacent and spaced fromthe upper or lower edge of the completed car end sufficiently to form inthe finished car end the requisite width of flat marginal portion atthis edge of the plate, the second corrugation being spaced inwardlyfrom said first corrugation the preset distance required of thecorrugations of this set in the finished car end, then heating theportion of the plate next to be die formed, locating the secondcorrugation with its associated portion of the vertical corrugations onthedie which formed the first corrugation so as to be held thereby frommovement in two directions at right angles to each other in the plane ofthe plate, die forming the next horizontal corrugation and itsassociated portion of the vertical corrugations to join with thepreceding portions of the vertical corrugations, and continuing thesuccessive beatings and die forming operations until the corrugated areais completed.

2. The method of forming a corrugated sheet metal plate consisting insubjecting succeeding portions of a flat metal plate to the repeatedaction of the same dies to form the plate with corrugations in sequencewith each corrugation including a longitudinal element and a pluralityof transverse elements forming the design in plan of a patriarchal crossand locating the transverse elements of each succeeding corrugation inline to form continuations respectively of the correspondinglytransverse elements of the next proceeding corrugation. I

3. The method'of forming a sheet metal plate with two sets ofintersecting corrugations to form a checkerboard effect, consisting insuccessively pressing corrugations, each in the form of a patriarchalcross in plan and constituting a unit of a repeated pattern form in planand constituting a unit of a repeated pattern form, in a flat metalplate in sequence with the ends of certain of the corrugations taperedand terminating short of the adjacent margins of the plate andsuccessively protecting the next preceding previously formed corrugationof the series from deformation while holding the plate as a whole in itsinitial fiat form.

4. The method of forming a sheet metal plate with two sets ofintersecting corrugations to form a checker-board effect, consisting insuccessively pressing corrugations, each in the form of a cross, in aflat metal plate in sequence with at least one corrugation Opening intoand aligned with its companion in the next unit with the ends of certainof the completed corrugations tapered and terminating short of theadjacent margins of the plate and successively protecting the nextpreceding previously formed corrugation of the series from deformation,and at each pressing clamping the area, including the previ ously formedcorrugation, surrounding the area being formed into the next succeedingcorrugation.

5. In the art of forming corrugations in metal plates and whereincertain of parallel corrugations have their ends spacedfrom the adjacentedges to form flat marginal areas, the method of forming a succeedingone of said parallel corrugations following the previous formation ofthe next preceding corrugation, said method including the step ofheating the area to be die formed, die-forming said succeedingcorrugation while clamping the preceding relatively cold corrugation inits formed configuration and while clamping in its flat form the balanceof the relatively cold area about the area at the time being formed intosaid succeeding corrugation.

6. In the art of forming corrugations in metal plates and whereincertain of parallel corrugations have their ends spaced from theadjacent edges to form fiat marginal areas, the method of forming asucceeding one of said parallel corrugations following the previousformation of the next preceding corrugation, said method including thestep of die-forming said succeeding corrugation while clamping thepreceding corruga-' tion in its formed configuration and while clampingin its fiat form the balance of the area about the area at the timebeing formed into said succeeding corrugation, while subjecting themarginal area beyond the ends of the corrugation being formed to a flatclamping action of sufiicient holding effect to form or maintain theflat marginal areas at opposite edges of the plate and thus avoidcrimping or puckering in such areas and said clamping action beinginsuificient to prevent creeping of the metal from said fiat edge areasinto the corrugations.

'7. In the art of forming a corrugated panel from a sheet of metal andwherein the corrugations form a repetition of a unit pattern, eachincluding a major corrugation and a minor corrugation extending at rightangles to its associated major corrugation and in alignment with thecorresponding minor corrugation on the next adjac'ent pattern unit, themethod which consists in subjecting a portion of the sheet to a flat diepressing operation to form completely one unit of the pattern Whileholding the sheet from moving and repeating the operation on asucceeding portion of the sheet displaced from the preceding portion inthe direction of the length of the preceding minor corrugation.

8. In the art of forming a corrugated panel in which certain of thecorrugations are arranged parallel to each other and other corrugationsare disposed at right angles to the parallel corrugations, the methodwhich consists in die pressing a limited portion of a sheet metal platewhile the plate is held stationary to form one of the parallelcorrugations and the adjacent portions of the other corrugations, whileflexing an adjacent portion of the plate and repeating said operation onthe next adjacent portion of the plate.

9. In the art of forming corrugated areas in sheet metal car ends and inwhichthe corrugations are arranged in checker-board fashion inintersecting sets, the method which consists in subjecting a flat sheetof metal to a heating and then immediately to a succession of diepressing operations beginning adjacent one edge and proceeding step bystep towards the opposite edge and at each succeeding die pressingoperation forming a corrugation of one set spaced a requisite distancefrom the similar previously formed corrugation of said set, and at thesame time forming the intersecting parts of the other set of a lengthprojecting laterally from the single corrugation being formedsufficiently long to meet and form a continuation of the same formedduring the next succeeding pressing operation, and at each operationholding the uncorrugated part of the sheet immediately adjacent thecorrugation being formed and which part is to be corrugated at the nextstep in its fiat condition to prevent the same from buckling.

10. In the art of forming a sheet metal panel including in its finalform two sets of corrugations the corrugations of one set each having arelatively Wide flat top and the corrugation of the other set being eachsubstantially U-shaped in cross section and hurdling over the Wide fiattop corrugations without change of cross sectional form, the methodwhich consists in initially forming in a sheet of metal, a singlecorrugation having on opposite sides of the crown thereof a plurality ofshort parallel corrugation sections transverse to the singlecorrugation, leaving the balance of the sheet fiat for the time being,and then simultaneously subjecting the single corrugation so formed totwo die forming operations, one displacing the previously formedsections in a direction away from the plane of the sheet to a distanceequal to thedepth of the hurdled corrugation in the finished panel andat the same time forming the single corrugation into a single flattopcorrugation extending across the parallel corrugations and hurdledthereby and repeating said operation to form a second set of hurdledcorrugations and associated hurdling corrugation sections, the latterlocated to form a continuation of each of the first formed hurdlingcorrugations.

